Engine Airflow Development Video Seminar DVD's

This exclusive video considered must-have training for airflow development engineers, technicians and base design engineers is presented by Ken Sperry, manager for power development/ gasoline engines at General Motors, and Pat Baer, engine performance specialist and airflow coordinator for Chrysler Corp. As the experts lead you into a think like air mindset, you will:
  • Learn the secrets of engine airflow dynamics in IC engines.
  • Discover how to create more power and engine efficiency.
  • See hands-on demonstrations of the tools used to measure airflow development progress.
  • Hear expert answers to real-world questions about airflow development, and much more.
  • Test the flow efficiency of cylinder head ports and other engine components.
  • Operate airflow measuring devices to reveal critical flow situations.
  • Solve crucial airflow problems using flow meters.
  • Capture vital data using the airflow bench.
  • Optimize combustion stability by producing adequate mixture motion (swirl and tumble) in the chamber and port.
  • Construct the most frequently-used port airflow measurement tools.
  • Develop inlet ports that maximize airflow capacity and improve the engines hp output.
  • Optimize your combustion chamber to get good airflow through the exhaust port.
  • Maximize inlet manifold airflow.
  • Reduce restriction in an exhaust manifold.
  • Use cutting-edge airflow benches.
  • Accurately define the design of an existing part.
Section 1
Airflow Development, Introduction and Background Video
  • Airflow bench test procedures (port flow and restriction)
  • Airflow bench limitations
  • Objectives of airflow development
  • Improve volumetric efficiency.
  • Minimize port / runner volume.
  • Quantify in-cylinder mixture motion.
  • Develop design guidelines.
  • Isolate restrictive components.
  • Setting airflow goals
  • Simulation errors
Walk through the cylinder head airflow test procedures.
1. Valve in test cylinder opened to set lift point.
2. Bench is set to standard differential pressure.
3. Data is recorded as airflow at that lift point (mixture motion recorded also.)
4. Process is repeated at other lift points.

What is KPA?
Video shows airflow data chart for intake port and exhaust port flow; and chart for mixture motion (swirl and tumble). In addition, the video covers Computational Fluid Dynamics (CFD) programs, the tool of the future (especially for mixture motion analysis), and has 3D animation of airflow (simulations were done on a Cray computer for Mitsubishi; with velocity in various colors) moving through clean air duct.

Walk through Component Airflow Restriction Test used to test flow efficiency of components other than cylinder head ports. Airflow is set at a given differential pressure and the change in mass flow rate is recorded. Shows chart with two runners on intake manifold.

Airflow bench limitations: big difference between how data is taken on a steady state airflow bench and in the engine. Not used widely until fairly recently.

Section 2
Airflow Measuring Devices


Understanding how airflow-measuring devices indicate flow, helps visualize critical flow situations.

Areas covered:
  • Several types of flow meters will be discussed along with a generic explanation of their operating principals.
  • Understanding these principals is the first step in solving many airflow problems
  • Discusses these devices to measure airflow:
  • Sharp Edged Orifice (S.E.O.) Superflow bench uses this
  • Pitot tube (velocity probe) - Pitot (pronounced pito) tubes are what airplanes use
  • Laminar Flow Element (L.F.E.)
  • Displacement type
  • Hot Wire Anemometry (HWA aka film anemometry)
  • Vortex shedding
Section 3
Test Standards and Conditions


Test standards and conditions (how to set components up on the airflow bench to capture and evaluate the data).

Areas covered:
  • Test differential pressure.
  • For port flow development (not the same on the engine as it is on the airflow bench).
  • Video talks about stall aka flow separation.
  • Video walks through the tests done to resolve this problem: ports showed improvement on the airflow bench but lost power on the engine.
  • Bore fixturing.
  • Make the bench look like the engine (airflow bench bore adapter should be the exact size of the engine bore).
  • Valve lift fixturing
  • Entry conditions
  • Airflow / area evaluation
Section 4
In-cylinder Mixture Motion


If you are a racer or OEM cylinder head designer, video discusses what you need to know about mixture motion. Even if your only concern is increased volumetric efficiency, mixture motion can affect the engine's output by varying the spark requirement between cylinders.

Areas covered:
  • Burn Rate Definition
  • Effects of Variation
  • Combustion Analysis
  • Flow Model Development
  • Single Cylinder Combustion Analysis
  • Single Cylinder combustion testing evaluates:
  • Idle and part throttle stability
  • Camshaft overlap sensitivity (Internal EGR)
  • Driven by valve area and backpressure
  • Engine - out emissions
  • Dilution tolerance
  • Added E.G.R.
  • Knock limited torque and octane requirement
  • Compression ratio trade-offs
  • Multi Cylinder Combustion Analysis
  • Swirl defined. Advantages:
  • Faster burn rate (Less time for something bad to happen)
  • More consistent burn rate (WOT)
  • Improved E.G.R. Tolerance
  • Improved part throttle stability (usually)
  • Tumble defined. Advantages
  • Faster burn
  • Combustion stability
  • E.G.R. Tolerance
  • Ability to operate on lower octane fuel
Section 5
Making Special Tools For Cylinder Head Testing

Over the years, several tools have been developed, for port development. The key to the success of each tool is the ability to take measurements while air is flowing through the port. This section will detail the tools and how to make them.

Special tools are:
  • Inlet port velocity probe
  • Flow restriction balls.
  • Thread wand.
  • Velocity probe valve.
  • Impact pressure probe.
Section 6
Inlet Port Development (Flow)


What you need to know to do port development (i.e. get more air through the hole.) The goal is an adequate amount of airflow capacity to meet hp requirements of the engine.

Areas covered:
  • Functional requirements
  • Flow model attributes
  • shows the attributes it should have
  • Area scheduling
  • Port velocity
  • Inlet port length impacts down stream airflow patterns (Mixture motion and flow)
  • Tuning the short turn
  • Boundary Layer Control
  • To visualize this, we need to understand laminar and turbulent flow.
  • Using the Tools
Section 7
Mixture Motion Development


Optimize combustion stability by producing adequate mixture motion (swirl and tumble) in the chamber and port.

Areas covered:
  • Functional requirements.
  • Types of mixture motion required.
  • Developing Swirl with the port.
  • Developing Swirl in the chamber.
  • Developing Tumble with port.
  • Developing Tumble in the Chamber.
Section 8
Combustion Chamber and Exhaust Port Flow Development


Optimize combustion chamber to get good airflow through the exhaust port.

Areas covered:
  • Chamber Philosophy
  • Minimize combustion chamber volume to run a flat top piston.
  • Development for flow, Chamber
  • Initial seat configuration
  • Exhaust port testing
  • Exhaust Port Development
Section 9
Inlet Manifold Flow Development


Maximize inlet manifold airflow, determine the restriction that the runner adds to inlet flow track and evaluate the plenum air entry options.

Areas covered:
  • Entry condition. (I.e., Plenum to port entry, etc.)
  • Least turns! (A: Runner, B: Plenum)
  • Throttle to Plenum expansion rate
  • Runner Shape
  • Runner taper
  • Throttle Noise
Section 10
Exhaust Manifold Flow Development


How exhaust manifolds work on the engine and what you can and cannot do on the airflow bench to develop exhaust manifolds. Cannot develop tuning on the airflow bench. The objective of airflow testing exhaust manifolds is to reduce the restriction for a given design.

Areas covered:
  • Limitations
  • Usual manifold design
  • Bead flow testing
  • Design guidelines
Section 11
Airflow Benches (Types)


Learn about the various types of airflow benches.

Areas covered:

Airflow bench types
  • Sharp Edged Orifice (S.E.O.) Type, the most popular type of steady state airflow bench.
  • The SEO Type benches are robust and reliable, not sensitive to dirt, and there are thousands of them in service.
  • They are the closest thing we have to an Industry Standard.
  • Because the Superflow benches are so popular, all the operators tend to speak the same Language.
  • Laminar Flow Element (LFE) type
  • The L.F.E. Airflow bench has proven to be reliable, repeatable, and capable of a wide flow and pressure range. But is relatively expensive to build (>$60K).
  • Meriam L.F.E.?S are traceable to the National Institute of Science and Technology, (N.I.S.T.).
  • Because the L.F.E. output is linear, it is easily interfaced with data acquisition systems.
  • Sonic nozzle type
  • The sonic nozzles are very repeatable, and traceable to
  • N.I.S.T. for calibration values.
  • Mixture motion measurement
  • Swirl
  • Tumble - We will discuss three methods, but there are several others:
  • The GMPT Load platform type
  • The GMR / FEV rotating Hoop type
  • The LEP Load Summing type
Section 11
Airflow Benches (Types)


Section 12
Reverse Engineering


Good for when you do not have design info for a head. Helps you copy an existing part (the act of creating design information from an existing part.

Areas covered:
  • Definition: Reverse Engineering
  • Introduction: Surface Data Acquisition
  • Capturing data
  • CMM
  • Laser scanner
  • Working around file size limitations
Engine Airflow Development Video Seminar DVD's
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